Methods for producing forged products and other worked products

ABSTRACT

Methods for producing forged products and other worked products are disclosed. In one embodiment, a method comprises using additive manufacturing to produce a metal shaped-preform and, after the using step, forging the metal shaped-preform into a final forged product. The final forged product may optionally be annealed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to U.S. Provisional PatentApplication No. 61/844,744, filed Jul. 10, 2013, and claims priority toU.S. Provisional Patent Application No. 61/845,260, filed Jul. 11, 2013,and claims priority to U.S. Provisional Patent Application No.61/895,046, filed Oct. 24, 2013, and claims priority to U.S. ProvisionalPatent Application No. 61/913,077, filed Dec. 6, 2013, and claimspriority to U.S. Provisional Patent Application No. 61/955,027, filedMar. 18, 2014. Each of these applications is incorporated by referencein their entirety herein.

BACKGROUND

Metal products may be formed into shapes via forging operations. Toforge metal products, several successive dies (flat dies and/ordifferently shaped dies) may be used for each part, with the flat die orthe die cavity in a first of the dies being designed to deform theforging stock to a first shape defined by the configuration of thatparticular die, and with the next die being shaped to perform a nextsuccessive step in the forging deformation of the stock, and so on,until the final die ultimately gives the forged part a fully deformedshape. See, U.S. Pat. No. 4,055,975.

SUMMARY

Broadly, the present patent application relates to improved methods forproducing worked metal products (e.g., forged metal products; othertypes of hot worked and/or cold worked metal products).

In one embodiment, a method includes using additive manufacturing toproduce a metal shaped-preform. After the using step, the metalshaped-preform may be forged into a final forged product. In oneembodiment, the forging step comprises a single die forging step. In oneembodiment, the metal preform comprises at least one of titanium,aluminum, nickel, steel, and stainless steel. In one embodiment, themetal shaped-preform may be a titanium alloy. For example, the metalshaped-preform may comprise a Ti-6Al-4V alloy. In another embodiment,the metal shaped-preform may be an aluminum alloy. In yet anotherembodiment, the metal shaped-preform may be a nickel alloy. In yetanother embodiment, the metal shaped-preform may be one of a steel and astainless steel. In another embodiment, the metal shaped-preform may bea metal matrix composite. In yet another embodiment, the metalshaped-preform may comprise titanium aluminide. For example, in oneembodiment, the titanium alloy may include at least 48 wt. % Ti and atleast one titanium aluminide phase, wherein the at least one titaniumaluminide phase is selected from the group consisting of Ti₃Al, TiAl andcombinations thereof. In another embodiment, the titanium alloy includesat least 49 wt. % Ti. In yet another embodiment, the titanium alloyincludes at least 50 wt. % Ti. In another embodiment, the titanium alloyincludes 5-49 wt. % aluminum. In yet another embodiment, the titaniumalloy includes 30-49 wt. % aluminum, and the titanium alloy comprises atleast some TiAl. In yet another embodiment, the titanium alloy includes5-30 wt. % aluminum, and the titanium alloy comprises at least someTi₃Al.

The forging step may comprise heating the metal shaped-preform to astock temperature, and contacting the metal shaped-preform with aforging die. In one embodiment, when the contacting step is initiated,the forging die may be a temperature that is at least 10° F. lower thanthe stock temperature. In another embodiment, when the contacting stepis initiated, the forging die is a temperature that is at least 25° F.lower than the stock temperature. In yet another embodiment, when thecontacting step is initiated, the forging die is a temperature that isat least 50° F. lower than the stock temperature. In another embodiment,when the contacting step is initiated, the forging die is a temperaturethat is at least 100° F. lower than the stock temperature. In yetanother embodiment, when the contacting step is initiated, the forgingdie is a temperature that is at least 200° F. lower than the stocktemperature.

In one aspect, the final forged product is a component for an engine. Inone embodiment, the final forged product is a blade for a jet engine. Inanother embodiment, as described below, the final forged product is anengine containment ring.

In another aspect, a method may comprise using additive manufacturing toproduce a metal shaped-preform, and concomitant to, or after the usingstep, working the metal shaped-preform into a final worked product viaat least one of: (i) rolling, (ii) ring rolling, (iii) ring forging,(iv) shaped rolling, (v) extruding, and (vi) combinations thereof. Inone embodiment, the working is rolling. In another embodiment, theworking is ring rolling. In yet another embodiment; the working is ringforging. In another embodiment, the working is shaped rolling. In yetanother embodiment, the working is extruding.

When the metal shaped-preform comprises a Ti-6Al-4V alloy, the forgingstep may comprise heating the metal shaped-preform to a stocktemperature, and contacting the metal shaped-preform with a forging die.In this regard, the contacting step may comprise deforming the metalshaped-preform via the forging die. In one embodiment, the contactingstep comprises deforming the metal shaped-preform via the forging die torealize a true strain of from 0.05 to 1.10 in the metal shaped-preform.In another embodiment, the contacting step comprises deforming the metalshaped-preform via the forging die to realize a true strain of at least0.10 in the metal shaped-preform. In yet another embodiment, thecontacting step comprises deforming the metal shaped-preform via theforging die to realize a true strain of at least 0.20 in the metalshaped-preform. In another embodiment, the contacting step comprisesdeforming the metal shaped-preform via the forging die to realize a truestrain of at least 0.25 in the metal shaped-preform. In yet anotherembodiment, the contacting step comprises deforming the metalshaped-preform via the forging die to realize a true strain of at least0.30 in the metal shaped-preform. In another embodiment, the contactingstep comprises deforming the metal shaped-preform via the forging die torealize a true strain of at least 0.35 in the metal shaped-preform. Inanother embodiment, the contacting step comprises deforming the metalshaped-preform via the forging die to realize a true strain of notgreater than 1.00 in the metal shaped-preform. In yet anotherembodiment, the contacting step comprises deforming the metalshaped-preform via the forging die to realize a true strain of notgreater than 0.90 in the metal shaped-preform. In another embodiment,the contacting step comprises deforming the metal shaped-preform via theforging die to realize a true strain of not greater than 0.80 in themetal shaped-preform. In yet another embodiment, the contacting stepcomprises deforming the metal shaped-preform via the forging die torealize a true strain of not greater than 0.70 in the metalshaped-preform. In another embodiment, the contacting step comprisesdeforming the metal shaped-preform via the forging die to realize a truestrain of not greater than 0.60 in the metal shaped-preform. In yetanother embodiment, the contacting step comprises deforming the metalshaped-preform via the forging die to realize a true strain of notgreater than 0.50 in the metal shaped-preform. In another embodiment,the contacting step comprises deforming the metal shaped-preform via theforging die to realize a true strain of not greater than 0.45 in themetal shaped-preform. As mentioned above, the forging step may compriseheating the metal shaped-preform to a stock temperature.

In one aspect, the forging step may comprise heating the metal-shapedpreform to a stock temperature. In one approach, the metal shapedpreform is heated to a stock temperature of from 850° C. to 978° C. Inone embodiment, the metal shaped preform is heated to a stocktemperature of at least 900° C. In another embodiment, the metal shapedpreform is heated to a stock temperature of at least 950° C. In yetanother embodiment, the metal shaped preform is heated to a stocktemperature of at least 960° C. In another embodiment, the metal shapedpreform is heated to a stock temperature of not greater than 975° C. Inyet another embodiment, the metal shaped preform is heated to a stocktemperature of not greater than 973° C.

In one aspect, the step of using additive manufacturing to produce ametal shaped-preform may comprise adding material, via additivemanufacturing, to a building substrate thereby producing the metalshaped-preform. In one embodiment, the material is a first materialhaving a first strength and wherein the building substrate is comprisedof a second material having a second strength. The first material mayhave a first fatigue property and the second material may have a secondfatigue property. For example, a layer of a first material having lowstrength and high toughness could be added, via additive manufacturing,to a building substrate comprised of a second material having highstrength and low toughness, thereby producing a metal-shaped preformuseful, for example, in ballistic applications.

In one embodiment, the building substrate comprises a first ring of afirst material, and the using step comprises adding a second material,via additive manufacturing, to the first ring thereby forming a secondring, wherein the second ring is integral with the first ring. In thisregard,

In another aspect, the method may include, after the forging step,annealing the final forged product. In one embodiment, when the metalshaped-preform comprises a Ti-6Al-4V alloy, the annealing step maycomprise heating the final forged product to a temperature of from about640° C. to about 816° C. In another embodiment, when the metalshaped-preform comprises a Ti-6Al-4V alloy, the annealing step maycomprise heating the final forged product to a temperature of from about670° C. to about 750° C. In yet another embodiment, when the metalshaped-preform comprises a Ti-6Al-4V alloy, the annealing step maycomprise heating the final forged product to a temperature of from about700° C. to about 740° C. In another embodiment, when the metalshaped-preform comprises a Ti-6Al-4V alloy, the annealing step maycomprise heating the final forged product to a temperature of about 732°C.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of one embodiment of a method ofproducing 4 final forged product.

FIG. 2 is a schematic illustration of one embodiment of a method ofproducing a final forged product, wherein the method includes anoptional annealing step.

FIGS. 3-4 are charts illustrating data of Example 1.

FIG. 5 is a schematic illustration of one embodiment of a method ofproducing a final forged product, wherein the final forged productincludes an integral building substrate.

FIG. 6 is a schematic illustration of another embodiment of a method ofproducing a final forged product, wherein the final forged productincludes an integral building substrate.

FIG. 7 is an illustration showing the transverse orientation andlongitudinal orientations of a cylindrical preform.

FIG. 8 is a micrograph of one embodiment of an as-built Ti-6Al-4V metalshaped-preform, taken in the transverse direction.

FIG. 9 is a micrograph of one embodiment of a preheated Ti-6Al-4V metalshaped-preform, taken in the transverse direction.

FIG. 10 is a micrograph of one embodiment of a Ti-6Al-4V final forgedproduct, taken in the transverse direction.

FIG. 11 is a micrograph of one embodiment of an annealed Ti-6Al-4V finalforged product, taken in the transverse direction.

DETAILED DESCRIPTION

Reference will now be made in detail to the accompanying drawings, whichat least assist in illustrating various pertinent embodiments of the newtechnology provided for by the present disclosure.

One embodiment of the new method for producing forged metal products isillustrated in FIG. 1. In the illustrated embodiment, the methodincludes a step of preparing (100) a metal shaped-preform via additivemanufacturing, followed by forging (200) the metal shaped-preform into afinal forged product (e.g., a net-shape product or near net-shapeproduct). After the forging step (200), the final forged product mayrequire no additional machining or other processing steps, thusfacilitating a lower total cost of manufacturing. Furthermore, the finalforged product may realize improved properties (e.g., relative to a pureadditively manufactured component).

The additive manufacturing step (100) prepares the metal shaped-preform.Additive manufacturing, or 3-D printing, is a process where layers of amaterial are deposited one after another using digital printingtechniques. Thus, precisely designed products can be produced. The metalshaped-preform produced by the additive manufacturing step (100) may bemade from any metal suited for both additive manufacturing and forging,including, for example metals or alloys of titanium, aluminum, nickel(e.g., INCONEL), steel, and stainless steel, among others. An alloy oftitanium is an alloy having titanium as the predominant alloyingelement. An alloy of aluminum is an alloy having aluminum as thepredominant alloying element. An alloy of nickel is an alloy havingnickel as the predominant alloying element. An alloy of steel is analloy having iron as the predominant alloying element, and at least somecarbon. An alloy of stainless steel is an alloy having iron as thepredominant alloying element, at least some carbon, and at least somechromium. In one embodiment, the metal shaped-preform is an intermediateproduct in the form of a precursor to a blade for a jet engine.

Still referring to FIG. 1, once the metal shaped-preform is formed, themetal shaped-preform is forged (200). In one embodiment, the forgingstep (200) uses a single blocker to die forge the metal shaped-preforminto the final forged product. By forging (200) the metalshaped-preform, the final forged product may realize improvedproperties, such as improved porosity (e.g., less porosity), improvedsurface roughness (e.g., less surface roughness, i.e., a smoothersurface), and/or better mechanical properties (e.g., improved surfacehardness), among others.

Referring now to FIG. 2, in one embodiment, during the forging step(200), the dies and/or tooling of the forging process is at a lowertemperature than the metal-shaped preform. In this regard, the forgingstep may include heating the metal shaped-preform to a stock temperature(the target temperature of the preform prior to the forging) (210), andcontacting the metal shaped-preform with a forging die (220). In oneembodiment, when the contacting step (220) is initiated, the forging dieis a temperature that is at least 10° F. lower than the stocktemperature. In another embodiment, when the contacting step (220) isinitiated, the forging die is a temperature that is at least 25° F.lower than the stock temperature. In yet another embodiment, when thecontacting step (220) is initiated, the forging die is a temperaturethat is at least 50° F. lower than the stock temperature. In anotherembodiment, when the contacting step (220) is initiated, the forging dieis a temperature that is at least 100° F. lower than the stocktemperature. In yet another embodiment, when the contacting step (220)is initiated, the forging die is a temperature that is at least 200° F.lower than the stock temperature. In another embodiment, when thecontacting step (220) is initiated, the forging die is a temperaturethat is at least 300° F. lower than the stock temperature. In yetanother embodiment, when the contacting step (220) is initiated, theforging die is a temperature that is at least 400° F. lower than thestock temperature. In another embodiment, when the contacting step (220)is initiated, the forging die is a temperature that is at least 500° F.lower than the stock temperature.

In one aspect, after the forging step (200) the final forged product mayoptionally be annealed (300). The annealing step (300) may facilitatethe relieving of residual stress in the metal-shaped preform due to theforging step (200). In one approach, the metal-shaped preform comprisesa Ti-6Al-4V alloy and the annealing step (300) may comprise heating thefinal forged product to a temperature of from about 640° C. (1184° F.)to about 816° C. (1500° F.) and for a time of from about 0.5 hour toabout 5 hours. In one embodiment, the annealing step (300) may compriseheating the final forged product to a temperature of at least about 640°C. (1184° F.). In another embodiment, the annealing step (300) maycomprise heating the final forged product to a temperature of at leastabout 670° C. (1238° F.). In yet another embodiment, the annealing step(300) may comprise heating the final forged product to a temperature ofat least about 700° C. (1292° F.). In another embodiment, the annealingstep (300) may comprise heating the final forged product to atemperature of not greater than about 760° C. (1400° F.). In yet anotherembodiment, the annealing step (300) may comprise heating the finalforged product to a temperature of not greater than about 750° C. (1382°F.). In another embodiment, the annealing step (300) may compriseheating the final forged product to a temperature of not greater thanabout 740° C. (1364° F.). In yet another embodiment, the time is atleast about 1 hour. In another embodiment, the time is at least about 2hours. In yet another embodiment, the time is not greater than about 4hours. In another embodiment, the time is not greater than about 3hours. In yet another embodiment, the annealing step (300) may compriseheating the final forged product to a temperature of about 732° C.(1350° F.) and for a time of about 2 hours.

The contacting step (220) may comprise applying a sufficient force tothe metal shaped-preform via the forging die to realize a pre-selectedamount of true strain in the metal shaped-preform. In one embodiment,the applying a sufficient force step comprises deforming the metalshaped-preform via the forging die. As used herein “true strain”(ε_(true)) is given by the formula:

ε_(true)=ln(L/L ₀)

Where L₀ is initial length of the material and L is the final length ofthe material. In one embodiment, the contacting step (220) may compriseapplying sufficient force to the metal shaped-preform via the forgingdie to realize a true strain of from about 0.05 to about 1.10 in themetal shaped-preform. In another embodiment, the contacting step (220)may comprise applying sufficient force to the metal shaped-preform viathe forging die to realize a true strain of at least 0.10 in the metalshaped-preform. In another embodiment, the contacting step (220) maycomprise applying sufficient force to the metal shaped-preform via theforging die to realize a true strain of at least 0.20 in the metalshaped-preform. In yet another embodiment, the contacting step (220) maycomprise applying sufficient force to the metal shaped-preform via theforging die to realize a true strain of at least 0.25 in the metalshaped-preform. In another embodiment, the contacting step (220) maycomprise applying sufficient force to the metal shaped-preform via theforging die to realize a true strain of at least 0.30 in the metalshaped-preform. In yet another embodiment, the contacting step (220) maycomprise applying sufficient force to the metal shaped-preform via theforging die to realize a true strain of at least 0.35 in the metalshaped-preform. In another embodiment, the contacting step (220) maycomprise applying sufficient force to the metal shaped-preform via theforging die to realize a true strain of not greater than 1.00 in themetal shaped-preform. In yet another embodiment, the contacting step(220) may comprise applying sufficient force to the metal shaped-preformvia the forging die to realize a true strain of not greater than 0.90 inthe metal shaped-preform. In another embodiment, the contacting step(220) may comprise applying sufficient force to the metal shaped-preformvia the forging die to realize a true strain of not greater than 0.80 inthe metal shaped-preform. In yet another embodiment, the contacting step(220) may comprise applying sufficient force to the metal shaped-preformvia the forging die to realize a true strain of not greater than 0.70 inthe metal shaped-preform. In another embodiment, the contacting step(220) may comprise applying sufficient force to the metal shaped-preformvia the forging die to realize a true strain of not greater than 0.60 inthe metal shaped-preform. In yet another embodiment, the contacting step(220) may comprise applying sufficient force to the metal shaped-preformvia the forging die to realize a true strain of not greater than 0.50 inthe metal shaped-preform. In another embodiment, the contacting step(220) may comprise applying sufficient force to the metal shaped-preformvia the forging die to realize a true strain of not greater than 0.45 inthe metal shaped-preform. In yet another embodiment, the contacting step(220) may comprise applying sufficient force to the metal shaped-preformvia the forging die to realize a true strain of about 0.40 in the metalshaped-preform.

In one embodiment, the metal shaped-preform is a low ductility material,such as a metal matrix composite or an intermetallic material. In oneembodiment, the metal shaped-preform is titanium aluminide. Using thenew processes disclosed herein may facilitate more economical productionof final forged products from such low ductility materials. Forinstance, the low ductility materials may be forged using dies and/ortooling that are at a lower temperature than the low ductility material.Thus, in one embodiment, the forging is absent of isothermal forging(i.e., the forging process does not include isothermal forging), andthus can include any of the stock temperature versus die temperaturedifferentials noted in the above-paragraph.

In one aspect, the metal shaped preform is a titanium (Ti) alloy, andthus includes titanium as the predominant alloying element. In oneembodiment, a titanium alloy includes at least 48 wt. % Ti. In anotherembodiment, a titanium alloy includes at least 49 wt. % Ti. In yetanother embodiment, a titanium alloy includes at least 50 wt. % Ti. Inone embodiment, the titanium alloy comprises one or more titaniumaluminide phases. In one embodiment, the titanium aluminide phase(s)is/are one or more of Ti₃Al and TiAl. When titanium aluminides arepresent, the titanium alloy may include 5-49 wt. % aluminum. In oneembodiment, the titanium aluminide phase(s) comprise TiAl. In oneembodiment, the titanium alloy includes 30-49 wt. % aluminum, and thetitanium alloy comprises at least some TiAl. In one embodiment, thetitanium aluminide phase(s) comprises Ti₃Al. In one embodiment, thetitanium alloy includes 5-30 wt. % aluminum, and the titanium alloycomprises at least some Ti₃Al. In one embodiment, the titanium alloycomprises aluminum and vanadium.

In one embodiment, the metal shaped preform comprises a Ti-6Al-4V alloy(a titanium alloy having about 6 wt. % aluminum and about 4 wt. %vanadium). In this regard, the Ti-6Al-4V preforms may be heated to astock temperature of from about 850° C. (1562° F.) to about 978° C.(1792° F.). In one embodiment, the Ti-6Al-4V preforms may be heated to astock temperature of at least 900° C. (1652° F.). In another embodiment,the Ti-6Al-4V preforms may be heated to a stock temperature of at least925° C. (1697° F.). In another embodiment, the Ti-6Al-4V preforms may beheated to a stock temperature of at least 950° C. (1742° F.). In yetanother embodiment, the Ti-6Al-4V preforms may be heated to a stocktemperature of at least 960° C. (1760° F.). In another embodiment, theTi-6Al-4V preforms may be heated to a stock temperature of not greaterthan 975° C. (1787° F.). In yet another embodiment, the Ti-6Al-4Vpreforms may be heated to a stock temperature of not greater than 973°C. (1783° F.).

The final forged product may be used in the aerospace, aviation, ormedical industries, for example. The final forged product could be, forexample, a turbine or blade. In one embodiment, the final forged productis a blade for a jet engine.

As mentioned above, after the additive manufacturing step (100), themetal shaped-preform may be forged (200) to create a final forgedproduct. In other embodiments, after the additive manufacturing step(100), the metal shaped-preform may be processed via other forms ofworking (e.g., hot working) to create a final worked product. Forinstance, the working of the metal shaped-preform may also oralternatively include rolling, ring rolling, ring forging, shapedrolling, and/or extruding to create the final worked product. In someembodiments, the final worked product may realize improved properties,such as improved porosity (e.g., less porosity), improved surfaceroughness (e.g., less surface roughness, i.e., a smoother surface),and/or better mechanical properties (e.g., improved surface hardness),among others. In some embodiments, the final worked product may realizea predetermined shape. In some embodiments, the metal shaped-preform maybe ring rolled, ring forged and/or extruded (e.g., forced through a die)to create a hollow final worked product. In some embodiments, the metalshaped-preform may be rolled to produce a final worked product thatrealizes improved porosity. In some embodiments, the metalshaped-preform may be shape rolled to produce a final worked productthat realizes a predetermined shape (e.g., a curve having a specifiedradius).

As used herein, “ring rolling” means the process of rolling a ring ofsmaller diameter (e.g., a first ring having a first diameter) into aring of larger diameter (e.g, a second ring having a second diameter,wherein the second diameter is larger than the first diameter),optionally with a modified cross section (e.g., a cross sectional areaof the second ring is different than a cross sectional area of the firstring) by the use of two rotating rollers, one placed in the insidediameter of the ring and the second directly opposite the first on theoutside diameter of the ring. As used herein, “ring forging” means theprocess of forging a ring of smaller diameter (e.g., a first ring havinga first diameter) into a ring of larger diameter (e.g, a second ringhaving a second diameter, wherein the second diameter is larger than thefirst diameter), optionally with a modified cross section (e.g., a crosssectional area of the second ring is different than a cross sectionalarea of the first ring) by squeezing the ring between two tools or dies,one on the inside diameter and one directly opposite on the outsidediameter of the ring. As used herein, “shaped rolling” means the processof shaping or forming by working the piece (i.e., the metalshaped-preform) between two or more rollers, which may or may not beprofiled, to impart a curvature or shape to the work piece (i.e., themetal shaped-preform).

The step of preparing the metal shaped-preform via additivemanufacturing (100) may include incorporating a building substrate intothe metal shaped-preform. Referring now to FIG. 5, one embodiment ofincorporating a building substrate (400) into the metal shaped-preform(500) is shown. In the illustrated embodiment, material (450) is addedto a building substrate (400) via additive manufacturing (100) toproduce the metal shaped-preform (500). As used herein, “buildingsubstrate” and the like means a solid material which may be incorporatedinto a metal shaped-preform. The metal shaped-preform (500), whichincludes the building substrate (400), may be forged (200) into a finalforged product (600). Thus, the final forged product (600) may includethe building substrate (400) as an integral piece.

As mentioned above, a final forged product may realize an amount (e.g.,a pre-selected amount) of true strain due to the contacting step 220. Insome embodiments, the strain realized by the final forged product may benon-uniform throughout the final forged product due to, for example, theshape of the forging dies and/or the shape of the metal shaped-preform.Thus, the final forged product may realize areas of low and/or highstrain. Accordingly, the building substrate may be located in apredetermined area of the metal shaped-preform such that after theforging, the building substrate is located in a predetermined area oflow strain of the final forged product. An area of low strain may bepredetermined based on predictive modeling or empirical testing.

Referring now to FIG. 6, another embodiment of incorporating a buildingsubstrate (410) into a metal shaped-preform (510) is shown. In theillustrated embodiment, material is added to the building substrate(410) via additive manufacturing (100) to produce the metalshaped-preform (510). The metal shaped-preform (510) may be forged (200)into a final forged product (610). The final forged product (610)includes the building substrate (410) as an integral piece.

The building substrate may have a predetermined shape and/orpredetermined mechanical properties (e.g., strength, toughness to name afew). In one embodiment, the building substrate may be a pre-wroughtbase plate. In one embodiment, the shape of the building substrate maybe predetermined based on the shape of the area of low strain. In oneembodiment, the mechanical properties of the building substrate may bepredetermined based on the average true strain realized by the metalshaped-preform and/or the true strain realized within the area of lowstrain. In one embodiment, two or more building substrates may beincorporated into a metal-shaped preform. In one embodiment, thebuilding substrate comprises a pre-wrought base plate.

The building substrate may be made from any metal suited for bothadditive manufacturing and forging, including, for example metals oralloys of titanium, aluminum, nickel (e.g., INCONEL), steel, andstainless steel, among others. In one embodiment, the building substrateis made of the same material(s) as the rest of the metal-shaped preform.In one embodiment, the material added to the metal shaped preform may bea first material, whereas the building substrate may be made of a secondmaterial. In one embodiment, the first material may have a firststrength and the second material may have a second strength. In oneembodiment, the first material may have a first fatigue property and thesecond material may have a second fatigue property. In one example, thebuilding substrate may be a first ring of a first material. A secondmaterial may be added, via additive manufacturing, to the ring therebyforming a second ring of the second material, integral with the firstring.

Thus a ring-shaped metal shaped-preform comprising two differentmaterials may be produced. The ring-shaped metal shaped-preform may thenbe forged into a ring-shaped final forged product comprising twodifferent materials. In one embodiment, one or more engine containmentrings (e.g., one or more aerospace engine containment rings) may beformed by the method described above. For example the building substratemay comprise a first ring of a material which realizes high toughness. Asecond ring of a second material which realizes high strength may beadded, via additive manufacturing, to the first ring thereby forming ametal shaped-preform. The metal shaped-preform may then be forged intoan engine containment ring having an inner ring of high toughness andouter ring of high strength.

Example 1 Ti-6Al-4V

Several Ti-6Al-4V preforms are produced via additive manufacturing.Specifically cylindrical Ti-6Al-4V preforms were produced via an EOSINTM 280 Direct Metal Laser Sintering (DMLS) additive manufacturing system,available from EOS GmbH (Robert-Stirling-Ring 1, 82152 Krailling/Munich,Germany). The Ti-6Al-4V preforms were produced in accordance with themanufacturer's standard recommended operating conditions for titanium.The preforms were then heated to a stock temperature of about 958° C.(1756° F.) or about 972° C. (1782° F.). Next, some of the cylindricalpreforms were forged under various amounts of true strain and using adie temperature of about 390° C.-400° C. (734° F.-752° F.) to producecylindrical final forged products. The true strain was applied to thecylindrical preforms in a direction parallel to the axis of thecylinders. The remaining preforms were left unforged. Some of the finalforged products were then annealed at a temperature of about 732° C.(1350° F.) for approximately two hours to produce annealed final forgedproducts. Mechanical properties of the unforged preforms, the finalforged products, and the annealed final forged products were thentested, including tensile yield strength (TYS), ultimate tensilestrength (UTS) and elongation, all in the L direction, the results ofwhich are shown in FIGS. 3-4. For each level of strain, several sampleswere tested and the results were averaged. Mechanical properties,including TYS, UTS, and elongation were tested in accordance with ASTME8.

As shown, the forged Ti-6Al-4V products achieved improved propertiesover the unforged Ti-6Al-4V preforms. Specifically, and with referenceto FIG. 3, the forged Ti-6Al-4V products achieved improved ultimatetensile strength (UTS) over the unforged Ti-6Al-4V preforms. Forexample, the unforged Ti-6Al-4V preforms achieved a UTS of about 140ksi. In contrast, the forged Ti-6Al-4V products achieved improvedultimate tensile strength, realizing a UTS of about 149 ksi after beingforged to a true strain of about 0.4. Furthermore, and as shown in FIG.3, the forged Ti-6Al-4V products achieved improved tensile yieldstrength (TYS) over the unforged Ti-6Al-4V preforms. For example, theunforged Ti-6Al-4V preforms achieved a TYS of about 118 ksi. Incontrast, the forged Ti-6Al-4V products achieved improved tensile yieldstrength, realizing a TYS of about 123 ksi after being forged to a truestrain of about 0.4. As shown in FIG. 4, the forged Ti-6Al-4V productsachieved good elongation, all achieving an elongation of above 12% afterbeing forged.

Furthermore, the annealed final forged products achieved improvedproperties over the final forged products which were not annealed.Specifically, and with reference to FIG. 3, the annealed final forgedproducts achieved improved tensile yield strength (TYS) over thenon-annealed final forged products. For example the annealed finalforged products which were forged to a true strain of about 0.2 achieveda TYS approximately 10% higher than the final forged products which werenot annealed. Furthermore, and as shown in FIG. 3, the annealed finalforged products achieved similar ultimate tensile strength (UTS) to thenon-annealed final forged products. Thus, annealing the final forgedproducts increased TYS without sacrificing UTS. As shown in FIG. 4, theannealed final forged products achieved improved elongation compared tothe non-annealed final forged products.

FIGS. 8-11 are micrographs showing the microstructures of thecylindrical preforms and cylindrical final forged products of Example 1.All of the micrographs were taken in the transverse orientation and atthe midpoint of the cylinder. Referring now to FIG. 7, one embodiment ofa cylindrical final forged product is illustrated. In the illustratedembodiment, the final forged product has been forged in the Z direction.The X-Y plane shown in FIG. 7 is the transverse orientation and the X-Zplane is the longitudinal orientation. Referring back to FIG. 8, amicrograph of a Ti-6Al-4V preform produced via additive manufacturing isshown. As can be seen in FIG. 8, the microstructure consists oftransformed beta phase material with evidence of the prior beta phasegrains. FIG. 9 is a micrograph of a additively manufactured Ti-6Al-4Vpreform that has been preheated to a temperature of about 1750° F. Ascan be seen in FIG. 9, the microstructure after heating is transformedbeta phase material with the formation and growth of acicular alphaphase material. No primary alpha phase material is observed. FIG. 10 isa micrograph of an additively manufactured Ti-6Al-4V preform that hasbeen preheated to a temperature of about 1750° F. and then forged totrue strain of about 0.7 (e.g., a final forged product). As can be seenin FIG. 10 the preheating and forging steps result in a more refinedgrain structure, punctuated by the nucleation of primary alpha phasegrains interspersed in the matrix. These interspersed primary alphaphase grains are observed as the small, white, circular dots. FIG. 11 isa micrograph of an additively manufactured Ti-6Al-4V preform that hasbeen preheated to a temperature of about 1750° F., then forged to truestrain of about 0.7, and then annealed at a temperature of about 1350°F. (e.g., an annealed final forged product). As can be seen in FIG. 11,in addition to the small, circular grains of primary alpha phasematerial interspersed in the matrix, primary grains of alpha phasematerial have formed as well.

While various embodiments of the present disclosure have been describedin detail, it is apparent that modification and adaptations of thoseembodiments will occur to those skilled in the art. However, it is to beexpressly understood that such modifications and adaptations are withinthe spirit and scope of the present disclosure.

1. A method comprising: (a) using additive manufacturing to produce ametal shaped-preform; (b) after the using step (a), forging the metalshaped-preform into a final forged product.
 2. The method of claim 1,wherein the forging step comprises a single die forging step.
 3. Themethod of claim 1, wherein the metal preform comprises at least one oftitanium, aluminum, nickel, steel, and stainless steel.
 4. The method ofclaim 30, wherein the metal shaped-preform is comprises a titaniumalloy. 5-8. (canceled)
 9. The method of claim 1, wherein the metalshaped-preform comprises titanium aluminide.
 10. The method of claim 1,wherein the forging step comprises: heating the metal shaped-preform toa stock temperature; and contacting the metal shaped-preform with aforging die.
 11. The method of claim 10, wherein, when the contactingstep is initiated, the forging die is a temperature that is at least 10°F. lower than the stock temperature. 12-14. (canceled)
 15. The method ofclaim 10, wherein, when the contacting step is initiated, the forgingdie is a temperature that is at least 200° F. lower than the stocktemperature.
 16. The method of claim 1, wherein the final forged productis a blade for a jet engine.
 17. The method of claim 4, wherein thetitanium alloy includes at least 50 wt. % Ti and at least one titaniumaluminide phase, wherein the at least one titanium aluminide phase isselected from the group consisting of Ti₃Al, TiAl and combinationsthereof. 18-19. (canceled)
 20. The method of claim 17, wherein thetitanium alloy includes 5-30 wt. % aluminum, and the titanium alloycomprises at least some Ti₃Al.
 21. The method of claim 1, comprising:concomitant to or after the using step (a), working the metalshaped-preform into a final worked product via at least one of: (i)rolling, (ii) ring rolling, (iii) ring forging, (iv) shaped rolling, (v)extruding, and (vi) combinations thereof. 22-27. (canceled)
 28. Themethod of claim 4, wherein the titanium alloy is a Ti-6Al-4V alloy. 29.(canceled)
 30. The method of claim 2910, wherein the contacting stepcomprises applying sufficient force to the metal shaped-preform via theforging die to realize a true strain of from 0.05 to 1.10 in the metalshaped-preform. 31-43. (canceled)
 44. The method of claim 2910, whereinthe metal shaped preform is heated to a stock temperature of from 850°C. to 978° C. 45-49. (canceled)
 50. The method of claim 1, wherein theusing step (a) comprises: adding material, via additive manufacturing,to a building substrate thereby producing the metal shaped-preform. 51.The method of claim 50, wherein the building substrate comprises a firstring of a first material and wherein the using step (a) comprises:adding a second material, via additive manufacturing, to the first ringthereby forming a second ring, wherein the second ring is integral withthe first ring. 52-53. (canceled)
 54. The method of claim 1 comprising,after the forging step (b), annealing the final forged product.
 55. Themethod of claim 54, wherein the metal shaped-preform comprises aTi-6Al-4V alloy, and wherein the annealing step comprises heating thefinal forged product to a temperature of from 640° C. to 816° C.
 56. Themethod of claim 55, wherein the annealing step comprises heating thefinal forged product to a temperature of from 670° C. to 750° C. 57-58.(canceled)